Apparatus and method for monitoring and communicating data associated with a product/item

ABSTRACT

A condition monitoring system includes a radio frequency transponder module including an RFID chip having a first memory, and an antenna; at least one sensor module that monitors data related to the condition of an item and includes a second memory for storing the monitored data; and a communication interface that couples the at least one sensor module to the RFID chip of the radio frequency transponder module so that the sensor module is operative to communicate with the RFID chip by way of the communication interface and the RFID chip first memory is operative to store data related to the item.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/914,212, filed Mar. 7, 2018, which is acontinuation of U.S. patent application Ser. No. 13/771,005, filed Feb.19, 2013, now U.S. Pat. No. 9,946,904, which is a continuationapplication of U.S. patent application Ser. No. 13/535,304, filed Jun.27, 2012, now abandoned, which is a continuation application of U.S.patent application Ser. No. 12/982,842, filed Dec. 30, 2010, nowabandoned, which is a continuation application of U.S. patentapplication Ser. No. 12/832,855, filed Jul. 8, 2010, now U.S. Pat. No.7,982,622, which is a continuation application of U.S. patentapplication Ser. No. 11/655,860, filed Jan. 19, 2007, now U.S. Pat. No.7,764,183, which is a continuation-in-part application of U.S. patentapplication Ser. No. 11/112,718, filed Apr. 22, 2005, now U.S. Pat. No.7,495,558, which claims priority pursuant to 35 U.S.C. § 119(e) to U.S.Provisional Application Ser. No. 60/566,019, filed Apr. 27, 2004, thedisclosures of all of which are incorporated herein by reference hereinin their entireties.

FIELD OF THE INVENTION

The invention relates to an apparatus and a method for monitoring andcommunicating data associated with an item. More particularly, theinvention relates to RF smart labels and related sensors, software, andprocesses that may be used for monitoring, analyzing, and communicatingitem data, such as “freshness”, perishability, and/or time/temperaturedata.

BACKGROUND

Perishable items, such as chilled and minimally processed food items,vaccines, pharmaceuticals, blood, film, chemicals, adhesives, paint,munitions, batteries, soft drinks, beer, cosmetics, and many otheritems, each have a unique shelf life. Item quality is affected by anumber of factors that may be physical, chemical or biological innature, and that act together in often complex and interconnected ways.Temperature is usually a significant factor determining the longevity ofquality. Sensors have been proposed to monitor and report the shelf lifeor integrity of an item (e.g. how well the quality of the item has beenmaintained over time). U.S. patent application Ser. No. 11/112,718 (the'718 application), which is assigned to the present assignee and whichis incorporated herein by reference, describes a class of sensors thatutilize RF technology for communicating precise, temperature-dependent,shelf life, and other time-dependent sensor monitoring of perishableitems. The sensors may operate in conjunction with RF transponders (alsoknown as RFID or radio frequency identification devices), such as thoseused for tracking and tracing items. For example, the sensors may bedirectly or indirectly coupled to and/or integrated with an RFtransponder.

SUMMARY OF THE INVENTION

Embodiments of the present invention combine digital sensing and RFIDtechnology for input and output of sensing data. This makes possible anew class of sensors, including sensors that monitor and report theintegrity of an item (e.g., how well the quality of the item has beenmaintained). Embodiments of the present invention add an alternatevisual and/or audio communication interface to RF digital sensors forthe purpose of communicating shelf life and sensor data. This alternatevisual/audio communication interface may be used to set-up and configurethe sensor when an RF reader is not present, to locate an item orcontainer in various situations, including those where the RF reader maynot be working properly, offload sensor data in situations where RFreaders are not present, and in situations where the amount of sensordata is communicated faster in a non-RF manner. For example, embodimentsmay use user-activated push buttons, RF commands, sensor softwareautomatic activation, or visual/audio remote control to activate anddeactivate visual and/or audio communication.

In one embodiment of the invention, the sensor may use LEDs to signalshelf life status, respond to a “where are you” location request or setup a visual signaling scheme to receive or transmit sensor data.

In another embodiment of the invention, a visual display, such as anLED, LCD, or OLED, provides a specific number of different signalingschemes, based upon pulse length and pattern that generate a time domainpulse sequence, Morse code, or other coding algorithm. The signalingschemes may be used to signal shelf life status or item information,respond to a “where are you” location request or send and receive shelflife setup or history data. Alternatively, a sensor may use differenttypes of audio sounds signal to shelf life status, item information andalerts, and/or respond to a “where are you” location request.

In another embodiment, a sensor may use visual displays and audiblesignals to transmit information to a user indicative of two or moretypes of item data, such as data identifying a type of item and datarelating to the freshness, perishability and/or shelf life of the item.Visual and audible indicators may signal early warning alerts orspecific information (for example, by use of color or dot-dash typecoding). When an RF sensor/indicator is enhanced with visual/audiosignaling systems, the sensor data can be communicated to a user or aremote visual/audio receiver when RF readers are not available, when RFperformance is low, when data to be communicated by the sensor isextensive, and when a particular tagged item needs to be located.

In another embodiment, an elongated smart label or “long tag” includesan extended interface between the antenna/RFID device and the sensormodule, including a pair of inductors. The long tag provides a solutionthat allows a user to position the sensor module inside a package whilepositioning the antenna and/or RFID device outside of the package for RFreception. For best RFID performance and because standard RFID tagsoften include shipping or item identification data and/or barcodes, RFIDlabels may be adhesively attached to the outside of the tagged case.Placing the sensor module inside a package, such as a cold box, whileallowing the antenna to reside outside of the package provides variousadvantages. For example, and without limitation, the long tag allows foroptimal sensing and RF reception when used together with temperaturesensitive goods that are placed in a container lined with metal and/orcontaining ice or dry ice packs, which could reduce RFID readperformance. In one embodiment, the power supply or battery is placednear the antenna, remote from the sensor module. This allows the batteryto reside outside of a container, thereby eliminating risk that cold orfreezing temperatures cause battery voltage to drop. Additionally, along tag could be used to sense the temperature of cases located in themiddle of a pallet.

According to one aspect of the invention, a sensor is provided formonitoring and communicating data related to a perishable item. Thesensor is adapted to operate with an RFID device including an antennafor receiving signals from an RF reader. The sensor includes a sensormodule that monitors time and temperature of a perishable item, thatdetermines a current freshness status based on the time and temperature,and that selectively transmits data representing the freshness status.The sensor further includes a communication interface with the RFIDdevice. The interface allows an RFID reader to retrieve datarepresenting the freshness status from the sensor module and allows thesensor module to detect activation of the RFID device. An indicator iscommunicatively coupled to the sensor module. The indicator is adaptedto selectively activate and communicate the freshness status by use of ahumanly perceivable signal under control of the sensor module. Thesensor module is adapted to selectively activate the indicator inresponse to detecting activation of the RFID device.

According to another aspect of the invention, a method is provided forlocating a perishable item by use of an identification signal generatedfrom an RFID reader. The method includes providing a smart label that isattachable to a container including the perishable item. The smart labelincludes an RFID device and a sensor module that is communicativelycoupled to the RFID device. The sensor module includes an indicator forgenerating a humanly perceivable signal. The method further includesreceiving an identification signal from an RFID reader, detectingreceipt of an identification signal by the RFID device by use of thesensor module; and causing the indicator to generate a humanlyperceivable signal in response to the detected receipt of theidentification signal.

Other features are described and claimed below and/or are apparent fromthe drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A schematically illustrates an active RF/sensor including abattery according to one embodiment of the invention.

FIG. 1B schematically illustrates a sensor adapted to communicate dataassociated with an item according to another embodiment of theinvention.

FIG. 2 schematically illustrates an RF sensor having a directsensor-to-antenna connection according to another embodiment of theinvention.

FIG. 3 schematically illustrates a semi-passive RF sensor having aserial interface between sensor and RFID components according to anotherembodiment of the invention.

FIG. 4 schematically illustrates an active integrated sensor and RFIDmodule according to another embodiment of the invention.

FIG. 5 illustrates a user using an RFID sensor to locate a particularcontainer according to one embodiment of the invention.

FIG. 6 illustrates one embodiment of an extended smart label or “longtag” that includes an extended interface between the antenna/RFID deviceand the sensor module, according to the present invention.

FIG. 7 illustrates an embodiment of an extended smart label or “longtag” that includes an extended interface that can be attached to anantenna/RFID device, including a pair of inductors.

FIG. 8 illustrates another embodiment of an extended smart label or“long tag” that includes an extended interface between the antenna/RFIDdevice and the sensor module, according to the present invention.

FIG. 9 illustrates the extended smart label or “long tag” shown in FIG.7 being placed into a container.

FIGS. 10A and 10B respectively illustrate a plan view and an elevationview of an embodiment of a display/switch that may be used with the RFIDsensors of the present invention.

FIGS. 11A-11D show an embodiment of a push-button switch that may beused with the display/switch shown in FIGS. 10A, 10B and the RFIDsensors of the present invention.

FIG. 12 is a block diagram illustrating programming components of an RFsensor in accordance with a preferred embodiment.

FIG. 13 is a further block diagram illustrating programming componentsand a modular configuration of memory of an RF sensor in accordance witha preferred embodiment.

FIG. 14 is a further block diagram illustrating programming components,a modular configuration of memory of an RF sensor coupled together withone or more further sensors in accordance with a preferred embodiment.

FIG. 15 is a further block diagram that illustrates separate RFID andsensor components that are at least signal coupled together.

FIGS. 16A and 16B schematically illustrate components of RFID sensors inaccordance with further embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiment of the present invention will now be described in detail withreference to the drawings, which are provided as illustrative examplesof the invention so as to enable those skilled in the art to practicethe invention. Notably, the implementation of certain elements of thepresent invention may be accomplished using software, hardware,firmware, or any combination thereof, as would be apparent to those ofordinary skill in the art, and the figures and examples below are notmeant to limit the scope of the present invention. Moreover, wherecertain elements of the present invention can be partially or fullyimplemented using known components, only those portions of such knowncomponents that are necessary for an understanding of the presentinvention will be described, and detailed descriptions of other portionsof such known components will be omitted so as not to obscure theinvention. Preferred embodiments of the present invention areillustrated in the Figures, like numerals being used to refer to likeand corresponding parts of various drawings.

Embodiments of the invention are described below relating to RF smartlabels, tags, sensors, software, and processes particularly formonitoring and analyzing the shelf life of a perishable item (“product”and “item” are used interchangeably throughout this application). Forexample, the labels, tags, and sensors may be used to indicate thefreshness, perishability or shelf life of-an item, and/or to providelogistics and inventory management to RFID tracking and tracing ofitems. The '718 application, which has been incorporated by reference,describes labels, tags, and sensors that can be used to implement thepresent invention.

FIG. 1A schematically illustrates an active RF/sensor including abattery in accordance with one embodiment. A chip 600 having RFID andsensor components is energized by a battery 80 that is resident on thesensor. In each of the embodiments described with reference to FIGS.1A-16B, the sensor is provided preferably in a substantially planerlabel attached to affected or perishable items that monitor the itemintegrity, usability and safety of an item or an environment inconjunction with an RF transponder, such as RFID ultrahigh frequency(UHF), high frequency (HF), low frequency (LF), Zigbee, Bluetooth, orother radio frequency identification transponders. In the case ofperishable items, the sensors may include temperature, shelf life (theintegration of time and temperature), humidity, vibration, shock, andother sensors that determine how well the quality of a perishable hasbeen maintained. In the case of nonperishable items, sensors may includethe abovementioned sensors plus item specific sensors that monitor thewear and tear on a particular item.

FIG. 1B illustrates one embodiment of a shelf life sensor 10, accordingpresent invention. The sensor 10 includes a power supply or battery 12,a sensor module 14, and an indicator/switch 16. The sensor module 14 iscoupled to and receives electrical power from battery 12, which maycomprise a coin cell, flexible battery or other relatively thin powersupply. The sensor module 14 may include sensor logic, such as aconventional processor chip and/or circuitry, a memory module forstoring data, such as data related to a perishable item, freshness data,or data representing one or more predefined temperature-dependent shelflife trends, and a sensor component adapted so sense and/or detecttemperature and/or other item parameters. The sensor logic or processingcircuitry can compare data received from the sensor to trend data inmemory to determine the freshness, perishability, or shelf life of aparticular item. This may be performed in the manners described in the'718 application and/or U.S. Pat. No. 5,442,669 (the “'669 patent”),which is assigned to the present assignee and which is incorporatedherein by reference. In alternate embodiments, the sensor module 14 mayuse external memory, such as the memory contained in an RFID device, tostore item data, and sensor measurements.

The sensor module 14 preferably includes a conventional interface forcommunicatively coupling the module 14 to an RF transponder, asdiscussed in greater detail below in reference to FIGS. 2-4.Particularly, the sensor module 14 may be used in conjunction with an RFtransponder or other radio frequency identification (RFID) system usedto communicate data, locate, track, and trace items or monitor anenvironment. The sensor module 14 may also be used in conjunction withan RF communication interface such as Bluetooth or Zigbee. The sensormodule 14 is further coupled to the indicator/switch 16 and canselectively signal indicator/switch 16 in order to activate/deactivate(turn on and off) the indicator. In one embodiment, the structure ofsensor module 14 may include structures substantially similar to thesensor chips described in the '718 application.

The indicator/switch 16 may be communicatively coupled to the sensormodule 14 and may receive electrical power from battery 12. Theindicator/switch 16 may include a LED, OLED, LCD, light, or othervisual, audio, or otherwise humanly perceivable sensory indicator forproviding information regarding a monitored item and/or the freshness ofthe item that is being monitored. For example, the indicator/switch 16may comprise a multi-colored display (e.g., LED or LCD) adapted togenerate a different color based on a particular signal. In oneembodiment, the indicator/switch 16 may also include a conventionalelectrical or capacitive switch for selectively activating the displayand/or the sensor module 14, for example, by manually depressing theindicator/switch 16. The switch and display elements may be separatedevices that are communicatively coupled together. Alternatively, theswitch and display elements may comprise a single integrated component.For example, the indicator/switch 16 may be constructed in a “stacked”configuration, including a transparent cover or membrane, a visualindicator (e.g., an LED) located below the membrane, and electricalswitching circuitry below the indicator. When the membrane is depressed,the switching circuitry closes, which “wakes up” or activates the sensormodule 14 and/or display. For example, the sensor may be shaped like adot, approximately 3-6 millimeters in diameter, folded, with two or morelayers of stacked electronics, one of which is a switch, and one ofwhich is a display (or audio), so that when touched it flashes back inone or more colors, or in a dot-dash code or by RF, or other form ofcommunication to an acceptable reader, human, machine or otherwise. Inan alternate embodiment, display 16 may be replaced by and/or comprisean audible indicator, for example, a low power audible oscillator thatgenerates humanly perceivable sound.

FIGS. 10A and 10B illustrate one embodiment of a display/switch 16.Display/switch 16 includes a pair of LEDs 50, 52, which may comprise redand green LEDs, respectively, and a push-button switch 54. Integratedcircuitry 56 controls the operation and/or activation of LEDs 50, 52.The LEDs 50, 52, switch 54, and integrated circuitry 56 is electricallycoupled to the positive and negative poles of a thin battery cell 58.The LEDs 50, 52, switch 54, and integrated circuitry 54 may bepreferably adhered to the battery cell using a conventional adhesive.

FIGS. 11A-11D show one embodiment of a push-button switch 54 that may beused with the display/switch 16. The button can be dispensed using astandard machine tape. The button includes a conductive member 60 thatis attached to the top substrate or tape portion 62. A pair of adhesivespacers 64, 66 adhere to the substrate 62 and hold the conductive memberaway from the conductive leads 68, 70 below. The conductive leads 68, 70are separated by a small switch gap 72. When the button is depressed,the conductive member 60 is placed in contact with conductive leads 68,70. This forms and electrical connection between the leads and closesthe circuit.

The sensor 10 is preferably embodied in a substantially planar labelthat may be attached to affected or perishable items in order to monitorthe item integrity, usability and safety of an item or an environment.In the case of perishable item, the sensor modules 14 may includeconventional temperature, shelf life (the integration of time andtemperature), humidity, vibration, shock and other sensors thatdetermine how well the quality of a perishable has been maintained, suchas the sensors described in the '718 application and/or the '669 patent.In the case of non-perishable items, sensors may include theabove-mentioned sensors plus item specific sensors that monitor the wearand tear on a particular item.

In one embodiment, sensor 10 comprises a smart label that is adapted tobe attached to an item or container and that monitors temperature andtime. For example, the sensor may sense and integrate temperature overtime while referencing a data table containing the shelf life parametersfor a tagged item, as may be previously provided or understood by aperishable producer. These shelf life parameters and determinations mayinclude calculations based upon Arrhenius equations with additionalrefinements, depending upon the quality concerns of the perishableproducer. The result is a customized, item—specific, real-time indicatorof shelf life left and/or shelf life history.

In one embodiment, the sensor 10 generates a visible and/or audiblesignal that has a frequency, duration and/or periodic characteristicthat varies based on one or more factors. For example, the sensor 10 maygenerate one or more periodic signals representative of at least twofactors, such as type of item and its freshness. A first factor mayinclude, for example, a type or classification of a used to identify itby type or general class of &-items or goods. A second factor mayinclude a freshness of that particular item or good. Preferably, thefreshness is determined by the sensor module 14 in the manner describedin the '718 application. The sensor module 14 can communicate signals tothe indicator/switch 16 in order to visually and/or audibly indicate thefreshness of the item.

As an example of a visual indicator, a green dot generated by thedisplay 16 (e.g., an LED) may indicate a fresh item, while a red dot mayindicate a spoiled item. The same dot may flash with a period of onesecond, so that it is illuminated for a half second and off for a halfsecond periodically, to indicate a particular produce type. A differentproduce type may have a period of two seconds, and a medicine type mayhave a period of three seconds.

This signaling scheme may also be reversed, so that the dot illuminatesfor a duration corresponding to the freshness of the item, e.g., longerduration for fresher item. For example, a green dot may indicate producetype A, a red dot may indicate produce type B, and a yellow dot mayindicate a medicine item. The display may generate a periodic flashinggreen light to indicate a “freshness” percentage or shelf life of theitem. For example, the longer the period that the green light flashes,the shorter the shelf life of the item. Alternatively, the sensor mayuse a code may to communicate the percentage of the shelf life remainingor the number of days remaining. For example, three-second periods maycomprise months, two-second periods may comprise weeks, and one-secondperiods may comprise days. In this example, a three-second flash,followed by three one-second flashes, would represent a month and threedays of shelf life. In an alternate embodiment, the display includesboth dashes and dots for communicating information relating to item typeand shelf life using a code, for example, Morse code.

As an example, regarding audible signals, a high pitch sound mayindicate a fresh item, while a lower pitch sound may indicate a spoileditem. The same dot may sound-off for a predetermined time period (e.g.,one second), so that it generates sound for a first predetermined time(e.g., a half second) and is silent for a second predetermined time(e.g., a half second), to indicate a particular produce type. Adifferent produce type may have a different period (e.g., two seconds),and a medicine type may have another period (e.g., three seconds). Thesemay be reversed, so that the sound is heard for a duration correspondingto the freshness of the item, e.g., longer duration for fresher item.Alternatively, different sound types could be used, such as a B flattone to indicate produce type A, a C sharp tone for produce type B, anda D flat tone for a medicine item.

Referring now to FIGS. 2-4, the sensor 10 may be communicatively coupledto an RFID device or RF transponder 18, which may comprise aconventional RFID integrated circuit. In one embodiment, the sensor 10and RFID 18 may be integrated within a single device. In the embodimentshown in FIG. 2, the sensor module 14 has the ability to connect totransponder 18 via a direct current connection 22 to the transponder'santenna 20. In the embodiments shown in FIGS. 3 and 4, the sensor module14 connects to the transponder 18 via a one-wire or a two-wire interface24, respectively. The transponder 18 assigns a predetermined amount(e.g., 32 bits) of user read/write memory exclusively to the sensor. Thesensor may use this designated RF transponder memory to report sensorstatus and alerts, to generate a particular indication signal by use ofindicator/switch 16, and to send/receive sensor commands to/from an RFreader.

In the case of a multi-chip RF tag, the tag's circuit architecturesupports an RFID transponder chip with support for either a directcurrent connection to the RF antenna (FIG. 4) or for a one- or two-wireserial interface to a sensor integrated circuit (FIGS. 2-3), and apredetermine amount of read/write user memory. One or more sensorintegrated circuits provide sensing, sensing power management, sensingdata memory management and RF detection/interface to the RFIDtransponder. The system preferably includes a battery 12 for poweringthe sensor(s) and optionally enhancing the communication signal whensensor data is sent to an RF reader (although the system may also bepassively configured). The battery also can be used to support theinitiation of RF communication by the sensor.

The system includes a communication interface preferably having thefollowing features. First, it is configured to provide notification tothe sensor 10 that data or commands are being sent by an RF reader orother RF device including another sensor. The notification may beprovided from the RF transponder 18 or from circuitry in the sensor 10that is watching the RF data for sensor commands. The commands mayinclude a command from an RFID reader that corresponds to a particularRFID device. Alternatively, a sensor identifier command could be usedthat identifies a specific sensor using an identification code or serialnumber. The sensor identification may also be associated with acontainer or item. The interface may also be configured with the abilityfor the sensor, as part of its sensing operation, to store sensorstatus, and alert data into designated RF transponder memory. Theinterface preferably may also have the ability for the sensor and the RFreader or other RF device to send/receive commands and data usingdesignated RF transponder memory. In one embodiment, the interface hasthe ability for the sensor to bypass the RF transponder memory and toestablish a direct path from the RF reader to the sensor for the purposeof initial sensor configuration and for downloading sensor history.

Memory

The current RF transponder chip is preferably configured to addresslarge amounts of memory (8K bytes). For RF system performance reasons,the RF chip may actually be populated with as little as 8 to 256 bytesof physical memory. The RF reader's commands to the sensor chip may bethe RF transponder's unpopulated memory addresses, or pseudo memory.This command syntax enables no modification to the RF reader for sensorsupport. Alternatively, the RF reader commands to the sensor can bespecial commands involving RF reader software that is modified tointerpret the commands.

The RF transponder may be configured to ignore illegal commands. It mayor may not issue an error message when it sees illegal commands. Thisenables the sensor commands sent by the reader to be placed in thedesignated memory area for the sensor.

It is preferred that the RFID sensor-transponder used as a label fortracking and tracing goods be inexpensive. As a result, the transpondersensor may be powered by a remote RF reader or inexpensive battery andcontain as little memory as possible, e.g., 64-2048 bits, even thoughthe RFID chip may be capable of addressing up to 8 k bits of memory.

A shelf life monitoring design may include a two-chip system (FIGS.2-4), or alternatively may include a single chip that exhibitstwo-functions within the chip. A shelf-life chip or module may be usedto treat an RFID memory as an input/output pipe to an RF reader. Memoryused for RFID applications is treated separately from shelf-life memory.Shelf-life memory may be accessed through one or more 32-bit blocks ofthe RF memory. In a two-chip implementation, a shelf life chip maycommunicate to an RFID chip via serial interface over a 1-wire bus.

In order to make a shelf-life memory more accessible and usable by an RFreader, shelf life memory addresses may be named based upon unusedaddresses in the RFID memory (i.e., memory addresses over 2048 bits to8000 bits). When an RF reader sends an address over and above physicalmemory in the chip, the RFID chip routes the address to the shelf lifememory. Data in this memory address on the shelf life chip is sent overthe 1-wire bus to the 32-bit memory block on the RFID chip and thentransmitted via radio frequency to the RF reader.

Although primarily shelf life monitoring is described herein, the shelflife chip may be designed to support multiple sensors, such as humidityor vibration. This sensor data is assigned these pseudo RF addresses,access to which is through the shelf life chip to the RF memory and outto the reader.

Power Management

The sensor 14 preferably performs its sensing operations at intervalsspecified by the user. As illustrated at FIGS. 1-4, the sensor isbattery operated. To conserve battery power, the sensor 14 sleepsbetween sensing intervals. At the predetermined sensor interval, thesensor wakes up, acquires the sensor data and analyzes the sensor datato determine exception conditions. For example, it preferably calculatesthe percentage of item life used for the time interval. The sensor 14may determine that a threshold has been exceeded. The sensor then copiesthe results of its exception calculations/alerts to the RF transponder'smemory and returns to sleep. This data is sent by the RF transponder tothe RF reader or other RF device in accordance with its normal RFoperations.

If the RF reader or other RF device requests more sensor information, itdoes so by sending commands to the RF transponder for the sensor.Advantageously, how the sensor is notified that the RF reader has orwants sensor data is dependent upon the physical interface betweensensor and RF transponder. If the physical interface is via directcurrent from the antenna, the sensor watches for RF signals to the RFtransponder, determines when a communication link between the attachedRF transponder and RF reader has been established, determines when datahas been written to the designated RF transponder memory and optionallydetermines if a special sensor command has been sent by the RF reader.If the physical interface is a one- or two-wire serial interface, the RFtransponder notifies the sensor that the RF reader has or wants data.

When the sensor 14 has been notified of a request for data, it wakes up,and reads/writes the data requested into the RF transponder's memory. Itthen goes back to sleep.

There are situations when the amount of data sent or received is large,for example, when the RF reader loads sensor configuration data andhistory collection rules into the sensor 14 and when the sensor 14 haslog and history data to be downloaded. In these situations, the sensorinterface allows sensor to by-pass the RF transponder's memory forsending or receiving blocks of data. The result is the establishment ofa direct connection between the sensor 14 and the RF reader.

The system is preferably configured to sense, then summarize data in thesensor memory (shelf life % left, hi/lo temperature thresholds exceeded,time elapse exceeded), then look for exceptions by comparing the summaryto conditions preconfigured by the user and finally to alert user thatall is ok or not. This summary info and alerts uses very little memory,and immediately after the sensing, it is put into the RF memory as“quick alerts”. Once quick alerts are in the RFID memory, they are readlike any other RF data, even when the sensor is asleep or in anotherwise low power state. The sensor also keeps history for later usein insurance claims, which can be downloaded upon command by user.

The embodiments described herein generally relate to means for enablinga discrete sensor or multiple discrete sensors to be added onto, coupledwith or piggyback attached to an RF transponder component for thepurpose of communicating sensor data to and from remote RF computerdevices and networks. A sensor communication interface is provided to anRF transponder for the purpose of communicating sensor alerts andhistory to an RF reader. A sensor architecture is provided for themanagement of sensor data. A method for physically mounting thesensor(s) onto an RF or RFID tag is also provided. Straightforwardtransition is enabled from discrete components to a combined sensor-RFintegrated circuit, permitting sensor RF tags to be tested usingdiscrete components until volume demands an integrated solution.

Further Transponder—Sensor Configurations

FIGS. 16A-16B schematically illustrate a freshness tag in accordancewith a preferred embodiment. The tag includes an RFID chip 1400 coupledwith an antenna 4000 for communicating with an RFID reader. A battery8000 is included for energizing the tag permitting the tag to operate attimes when a reader is not communicating with it. The battery 8000permits freshness monitoring and updating at selected times so thatfreshness status can be updated within the memory and at the displayindependent of reader interaction. The sensor chip 1600 includes asensor component 2200 and logic 2400. The sensor 1600 periodicallymeasures time and temperature and determines freshness based on pasthistory and calculation based on spoilage rate tables or formulas. Thefreshness status is updated and stored in a memory location that isaccessible by an RFID reader communicating with the RFID chip 1400independent of the sensor 1600.

The described embodiments are advantageously configured in order for theRF transponder-sensor systems to be widely used and desired, as case andpallet tags. The transponder unit costs are minimized in one or more ofthe following ways. First, minimal memory is provided in the transpondercomponent in order to optimize the read distance of transponder. Second,efficient power management is provided by battery control logicincluding the periodic monitoring capability of the sensor between sleepperiods and the accessibility of the freshness data directly by RFIDreader. Third, the system is general purpose in order to maximize RFunit volume and thus minimize unit cost. For an example, a memory sizeof EPC RFID UHF transponders used in the supply chain ranges from 64- or96 bits for Class 0 and 288-bits for Class 1 Gen2. In alternativeembodiments, passive RF transponders may be used, wherein the power forthe transponder is provided by a remote RF reader, with the RF reader'sobjective to keep power required by the RF transponder to a minimum. Inthe case of active (battery-powered) RF transponders, memory size of thetransponder can be larger as the battery can be used to enhance thesignal from RF tag to reader.

Sensors, in contrast, are dictated by needs of a particular item orclass of item as to what sensors and what sensor data is to becollected, and what spoilage curves are obeyed by particular item. Thesecan be either memory hungry (in order to store sensor data over the lifeof the item) or require computational capability to summarize andcondense the sensing data. Sensors further utilize power managementoptimized around the sensing interval (not RF). Additionally, forsensors to be used for supply chain and logistics management, sensingdata is evaluated and summarized in the tag with exception and alertconditions able to be communicated quickly to RF readers. History iskept in the tag for backup for insurance claims or for use in analysisof what went wrong. Additionally, the sensor may be preferablyconfigured prior to start of sensing with sensing and history loggingrules, and other information too bulky to be part of real-time RFinventory logistics.

Programming and Data

FIGS. 12-15 illustrate chip and memory content configurations in blockdiagrams of an RFID transponder-sensor system in accordance withpreferred embodiments. FIG. 12 illustrates a sensor 280 having a twinoscillator or twin-clock system sensor component 300 that measurestemperature and time, preferably in accordance with U.S. Pat. No.5,442,669, hereby incorporated by reference, and in accordance with apreferred embodiment. The memory block 320 illustrated at FIG. 12includes several programming components for controlling variousfunctions of the sensor. The digital control, read/write control, andaccess control programming permit conversion of analog data and accessto the data, as well as data updating and downloading. Memory andexternal internal interface controls permit communication of data via anRFID transponder chip. These also permit the data to be transferred toanother tag such as in a mother-daughter tag system that may be usedwhen multiple item bundles are broken up along the supply chain. Thisfeature is advantageous when it is desired to continue monitoring thefreshness status of perishable items using past history and presentstatus when items are separated from a pallet or other large supplychain bundles. The programming further includes battery and displaycontrols. The shelf life component includes the tables or calculationformulas for determining current freshness data based on measurementdata received periodically from the sensor 300.

Accordingly, an RF-enabled sensor architecture is provided and describedherein including one or more discrete sensor(s) and an RF transponder,with these different functions being implemented as modules in anintegrated sensor/RF circuit system using the same memory addressing andcommand structure.

An advantage of the system is its custom-designed I-FRESH integratedcircuit. The I-FRESH-IC is designed to be processor-efficient,power-efficient, and memory-efficient, yet accurate, customizable, andauditable. The same I-FRESH-IC can be used to monitor shelf life of anitem with a 14-day life or a 3-year life.

The I-FRESH-IC has been designed first and foremost for shelf lifemonitoring, although it can be used simply as a temperature monitor. Thebasis of the design is its twin clocks, one of which is a wild clock andthe other which is a temperature-compensated clock. These provide aconsistency between time and temperature that is the basis of theaccuracy of the chip's shelf life (time-temperature integration)calculation over the life of the item. The clocks run at very slowspeed, resulting in power efficiency.

The I-FRESH-IC can be either a state machine or micro-processor. Itsprimary embodiment is the use of tables to calculate shelf life,although alternatively an expression may be used, and calculations maybe performed. Preferably, the sensor chip or I-FRESH-IC uses shelf lifedata provided by the perishable producers for calculating their item's“Use By” or expiration date. This data, expressed in % of shelf lifeused at each expected temperature, can take into account the effect ofthe item's packaging. The user can also include high or low temperaturethresholds which cannot be exceeded, for example, certain items cannotbe frozen or evaporated and conditions under which the user is to bealerted. This data can be input at the fab, distributor, or at theperishable producer. Once loaded into the chip, this data, as well asshelf life calculations and history, can be configured such it eithercan or cannot be modified, and can be read/write protected if desired.

When started, the chip sensor samples temperature at user-set intervals24/7 until the end of the item's shelf life. Preferably for food, thissample interval is set at 12 minutes for most items. But other samplerates are possible and configurable depending on life and desiredprecision.

In addition, the perishable producer, as well as other users of the tagwithin the supply chain (for example, shipper, distribution center orretailer), can set alert conditions. Examples of alerts: “ship at 90%shelf life left;” “sell at 50% of shelf life left;” and/or “/item is atfreezing”. Furthermore, history and exception conditions are preferablystored in the chip and can be accessed via an RF reader for printing orsaving to a database.

Depending upon battery life, the tag can be reused. Battery optionsprovide for a tag life of up to 10 years, although preferably a servicecall at twelve reuses or eighteen months is performed to maintainadequate calibration and battery life.

The RFID functionality of the tag may be passive RFID, i.e.,communication is initiated and enabled by active RFID readerinterrogation of the transponder-sensor system. The tags will supportEPC UHF, ISO UHF, ISO HF, ISO LF, and/or other RF communication asapplicable for communicating sensor data. The perishable producerpreferably specifies the RFID standard (EPC, ISO), frequency (UHF, HF,LF), and memory to be used for RFID use for its unique identificationnumber (EPC) and other uses (256, 512, 2048 bits).

An advantage that is illustrated at FIG. 14 is called “inheritance” andis described in more detail below. This feature enables shelf life leftfrom a large container of perishables to be transferred to a tag set upfor the same batch/shelf life characteristics. Examples include wine(vat, case, bottle); pharmaceuticals (large container, small container,vial). Inheritance also enables shelf life data to be transferred from aUHF pallet or case tag to an HF item tag. The inheritance feature mayalso be used for very long-life items, wherein a new tag may be used toreplace an old tag that may be at the end of its useful life. Althoughpreferably old tags simply have their data transferred to new tags, anold tag can alternatively be refurbished with new programming, a newbattery and even a replacement chip.

The I-FRESH-IC supports an optional display 16 with user button. Thedisplay is preferably a printable display 16, is flexible and may beconfigured for tagging applications on bottles or odd shaped items. Thedisplay can represent “fresh/not fresh,” “fresh/use now/toss,” or can beakin to a gas gauge ranging from “fresh” to “empty”. Other commonoptions, including red/green LEDs may apply.

The size of the tag, substrate to which the I-FRESH-IC and the antenna20 are mounted, the battery life and the optional display are preferablyconfigurable components of the tag. Physical tag size is determinedmainly by the antenna 20 and battery 12, which in turn may be selectedbased on desired accessible distances and lifetimes. The antenna 20 useswith UHF EPC can be as large as 4″ by 4″. HF antennas in contrast aresmaller in size and can fit on a 1″×2″ tag or on the top of a bottlecap. The battery 12 may include a 14-day, 190-day, 500-day, 3-year, or10-year life. These options include a printable battery (thin andflexible) or a button cell. Choice of battery is dependent upon size andnature of the item to be tagged and the shelf life of the perishable.

The sensor-transponder system is preferably configured in accordancewith Windows CE-based PDA readers and shelf/desk mountable readers forshort distance reading. Additionally, the preferred tags are compatibleto industry-standard ISO an EPC portal readers.

Real-time edgeware software is preferably used for readers and networks.The reader software enables readers to input, output, print andcommunicate shelf life data, alerts, and history. This network softwaremonitors shelf life readers on the network, gathers statistics, checksthat the readers are working, provides updates, and manages shelf lifedata tables. Its web database servers enable those with no supply chainsoftware systems to access shelf life data. It also offers developertoolkits and shelf life fine-tuning software, enables users to manageshipping, manufacturing, inventory, and sales by “least shelf lifeleft”.

Customized software is preferably utilized to interface to customerproprietary supply chain software systems. Interfaces to leading supplychain software systems such as Savi and SAP may be used, and specialinterfaces may be used.

FIG. 13 illustrates an RFID reader 400 communicating with asensor-transponder system 420 in accordance with a preferred embodiment.The sensor-transponder system 420 includes an RFID transponder component440 that includes a shelf life memory component 460 that is preferably32 bits. The memory component 460 is accessible by the reader 400independent of the sensor status, i.e., whether it is asleep ormeasuring or processing current freshness data. The transpondercomponent 440 includes an interface component 480 for communicating witha corresponding interface 490 of the main sensor memory 500. The display520 is illustrated as being controlled by the sensor 500, and thebattery 540 is illustrated for powering the sensor 500.

Shelf Life and Custody Logs

Over the last twenty years manufacturers, distributors and retailers ofperishables have used data loggers to collect temperature data for HACCPdocumentation and analysis of refrigeration equipment, transportationcontainers and warehouse air conditioning and refrigeration—flaggingwhen and how long temperature thresholds have been exceeded. At eachsensing interval the logger records time of the sensing andtemperature—resulting in logger memory commonly ranging in size from16K-64K bytes. When loggers are used to measure environmental conditionsin which items are stored rather than used to monitor tagged items, thelarge accumulation of historical data is not an issue. However, whentemperature loggers using RF as their communication interface are usedas tags on perishable items, cases or pallets, the amount of data to besent from the tag to the RF reader and system databases is massive. Theamount of data sent from a tag to a reader affects the number of tagsthat can be read by an RFID reader as tags pass through a warehouse doorand the amount of disk storage involved to save the tag's data.

Additionally, in order for the same log to accommodate a variety ofperishables, all with different lives (e.g. fish at 14 days, drugs atyear or longer, “meals ready to eat” at three years or more andammunitions at over five years), the logger's memory needs to be largeenough so that sensing data is not dropped when memory boundary of thelogger is reached.

In accordance with a preferred embodiment and referring to an exemplaryshelf life table illustrated at Table I, integration of temperature andtime into a % of shelf life used per sensing interval results in anumber representing shelf life left. As the tagged item passes thru anRF controlled warehouse door, this shelf life left number and any userset alerts quickly communicates the item's condition.

TABLE I Custody Shelf Life Elapsed Min Max Change Location # Left Time(min) Temp Temp Mfg stores 111111 100% 12 9.9 9.6 Truck 222222 99% 369.2 18.7 99% 48 5.2 18.5 Truck 222222 98% 156 4.5 5.0 Mfg DC 333333 98%160 4.7 5.2 dock 96% 168 4.7 33. Mfc DC 333444 96% 168 3.3 29.9 stores95% 468 1.1 29.8 94% 780 1.2 1.4 93% 1080 1.1 1.2 Transport 444444 93%1090 1.0 1.3 92% 1320 1.2 1.4 91% 1500 1.1 1.3 Alert 2 Be 90% 1680 1.41.2 at retail DC 89% 1860 3.3 4.8 Transport 444444 89% 1860 5.0 5.2Retail DC 555555 89% 1862 5.1 5.3 Dock 88% 1956 5.0 5.3 87% 2136 5.1 5.386% 2316 5.2 5.3 Retail DC 555566 80% 1864 4.9 5.2 Stores Alert 3: sell75%

History data is also preferably kept. This includes a histogram oftemperatures sensed and a shelf life log. The shelf life log preferablyrecords the elapsed time, the maximum temperature and the minimumtemperature for each % change in shelf life. This % change (e.g., 1%,0.5%, 5.0%) can be specified by the user. For example, if the log is setto log at each 1% change in shelf life, the log table has 100 entries(going from 100% to 1%); no matter what the actual life of the taggeditem. When temperature abuse occurs most entries in the logs are at thetime of the temperature abuse, e.g., occurring because the temperatureabuse causes greater percentage decrease in shelf life left. In analternative embodiment, a mean kinetic temperature log may be keptinstead of or in addition to the shelf life log.

The sensor also logs high and low temperature threshold violations andalert data. The result is exception-based reporting that is applicablenot only for temperature sensing but for any sensor data that affectsthe shelf life of an item, has settable alert conditions or hasthreshold settings—perishable or non-perishable.

Additionally, the sensor preferably updates its log at each change incustody (from inventory to receiving; from manufacturer to transport toretail distribution center to transport to retailer). Notification forthe change of custody is sent from an RF reader to the RF transpondermemory and then to the sensor. Custody data sent from the readerincludes, at a minimum, the time of the change of custody and thelocation or reader identification number.

The shelf life % used, temperature threshold violations, alerts andchanges in custody data require approximately 512 bytes of log memory.When this data is viewed together on one table/chart, the user gets aquick picture of what happened to the item case, or pallet. This is incontrast to an RF logger with its 16 k to 64K bytes of temperature datawhich has to be downloaded to an RF reader, then sent to a computer foranalysis.

Inheritance

FIG. 14 illustrates an RFID reader 400 communicating with a furthersensor-transponder system 620 in accordance with a further embodiment.There are many further situations in which items are shipped in largecontainers and throughout the distribution chain are repackaged. Thequality of a perishable is affected by the item's temperature historyand its perishability curve. Today when batches of pharmaceuticals aresplit into smaller batches often the “use by” date is lost.

The sensor-transponder 620 includes the components 440, 480, 490, 500,520 and 540 described previously with respect to the embodiment of FIG.13. The system 620 includes the further feature that additional smartsensors 640 and 660 are “daisy-chained” together with the system 620.Freshness status data from the memory 500 not only to the RFID readeraccessible memory 440, but also to the additional sensors 640 and 660 byinterfaces 680, 700, 720 and 740.

Freshness status data, shelf life data including output shelf life dataand other programming are contained in and/or are transferred to theadditional sensors 640 and 660. The additional sensors 640, 660 may bedetached from the main sensor 620. The additional sensors 640,660 canthen be attached to separated items from a bundle that the main sensor620 was and may continue to be attached to. The additional sensors640,660 may be configured only for retaining the freshness status dataobtained from the main sensor 620 and may be more completely configuredto continue to sense the freshness of the separated items to which theyare now attached. The additional sensors may only have a display forproviding freshness status, are may be further configured so that thefreshness data may be accessed by an RFID reader. The additional sensors640, 660 may also be re-attached to the same or another main sensormodule 620. In this embodiment, the additional sensors 640, 660 maypreferably utilize the RFID transponder, battery, display and memorycapabilities of the main sensor 620, and simply carry and transfer thefreshness status data upon re-attachment.

This inheritance feature enables shelf life data to be transferred toanother shelf life tag or additional sensors 640, 660. The new tag oradditional sensors 640,660 is/are configured with the same shelf lifetables or perishable data tables as the main sensor memory 500. Not onlyis the shelf life left but also an audit trail identifying the EPCnumber of the mother tag 620 are each preferably transferred to thedaughter tag(s) 640, 660. Particular applications include wine andpharmaceuticals.

FIG. 15 illustrates another embodiment of a sensor-transponder system.In this embodiment, a sensor component 80 and memory component 820 areseparate modules that connect and/or communicate via interfaces 840,860. The sensor component includes the memory 500, display 520 andbattery 540, while the memory component 820 includes memory 440 andcomponents for communicating with RFID reader 400.

Another embodiment of the sensor-transponder system is for shelf lifedata representing % of shelf life left, the time of last shelf lifereading, a calculated new expiration date based on the last shelf lifeand/or estimated time left before use to be communicated to a printedlabel.

ALTERNATIVE EMBODIMENTS

RF output of digital sensors is an alternative to the more commonlyimplemented serial interfaces for sensors. A radio frequency or infraredband can be substituted as a communication interface for a one-wire busfor communicating temperature and shelf life (see, e.g., U.S. Pat. No.6,122,704, hereby incorporated by reference).

A wireless tag may be attached to an item communicating to a reader suchas is described at U.S. Pat. No. 6,285,282, hereby incorporated byreference.

A timing module may be included that permits a user, upon interrogatingan RFID tag, to determine the precise length of time from the previouscharge of the RFID tag and how an environmental sensor can be used inconjunction with timing module (see, e.g., U.S. Pat. No. 6,294,997,hereby incorporated by reference).

Any of various ways may be selected for communication of wireless sensordata and communication to a remote reader. Various ways may be used forinterfacing the sensor to a non-sensor RF transponder for the purpose ofcommunicating sensor data to the RF transponder and ultimately to areader. The RF transponder then communicates the sensor data to an RFreader. For example, European Patent No. EP 0837412 A2, herebyincorporated by reference, describes memory mapping of special functionslike the read out of sensor data.

In addition, a display system and memory architecture and method fordisplaying images in windows on a video display may be used fordisplaying freshness status (see, e.g., U.S. Pat. Nos. 4,823,108 and5,847,705, hereby incorporated by reference). Further features may bedescribed at U.S. Pat. Nos. 5,237,669; 5,367,658; 6,003,115; 6,012,057;6,023,712; 6,476,682; 6,326,892; 5,809,518; 6,160,458; 6,476,716;4,868,525; 5,963,105; 5,563,928; 5,572,169; 5,802,015; 5,835,553;4,057,029; 4,277,974; 3,967,579; 6,863,377; 6,860,422; 6,857,566;6,671,358; 6,116,505; 5,193,056; 6,217,213; 6,112,275; 6,593,845;6,294,997; 6,720,866; 6,285,282; 6,326,892; 6,275,779; 4,857,893;6,376,284; 6,351,406; 5,528,222; 5,564,926; 5,963,134; 5,850,187;6,100,804; 6,025,780; 5,745,036; 5,519,381; 5,430,441; 4,546,241;4,580,041; 4,388,524; 4,384,288; 5,214,409; 5,640,687; 6,094,138;6,147,605; 6,006,247; 5,491,482; 5,649,295; 5,963,134; 6,232,870; and4,746,823, U.S. Published Patent Application No. 2002/0085453, and/orsensor interface spec 1451-4, and/or at the background, inventionsummary, and brief description of the drawings, and are all herebyincorporated by reference.

An independent display may broadcast an RF signal continuously within aperimeter of, e.g., ten feet, for energizing a responsive packagingdevice that signals back its perishability status. The signal may be amark along a gas gauge type device or a yes/no LED or OLED or PLED. Asingle dot may represent the polled package. The independent display maybe attached to a counter, a wall, a shelf, a refrigerator, a pallet,etc. This allows a substantial reduction in power and cost in monitoringthe shelf life of the package. The display may work in conjunction withother means to selectively poll an individual package. The package maybe individually switched on or off to avoid conflicts with other polledresponses. The display may search out other indicia to identify theindividual package, make a list of such, and append the perishabilitystatus to the list.

Shelf life is an integration over multiple temporal periods of aspoilage rate curve that varies as a function of temperature and/orother environmental conditions such as humidity, vibration, directexposure to contaminants or oxidation, etc. Preferably, as least twoclocks, one for measuring time and one for measuring temperature, areused. Tables may be used that take these into consideration, therebyproviding a shelf life accuracy that can be tuned for particular items.Shelf life accuracy is thereby provided over the life of the perishablewithin advantageously 1% in critical ranges. This accuracy is dependentupon the consistency of the clocks. Tables may be calibrated and loadedwith just clock tick data (representing temperature), to provide atemperature monitor.

Life left in the battery may be determined based upon a number of shelflife samples. For example, log RF may read and display hits. This may beadvantageous for determining battery status. At the end of a shelf life,a tag may go dormant, so that as to battery life, the tags may be reusedwith the remaining battery life that was saved due to the tag goingdormant when the shell life has expired. The shelf life left may berepresented as a percentage of shelf life. This may be kept in the chipvery accurately and yet may be a smaller percentage when sent to areader for alert purposes. The tag may be effectively an exceptionreporter, and as such may provide alerts and pinpointing of exceptions.

The tag may be an item tag for foods and pharmaceuticals, among otherperishable items. Reference data that enables an audit trail may beprovided in the tag. Once the tag is started, preferably no data (shelflife, use by alert, history and shelf life left) is to be changed by auser, although alternatively, a tag may be configurable as desired undercertain circumstances. A reason not to permit modification of data isthat inheritance of data (especially for beyond use dates) may provideaudit trail ability. The preferred embodiment includes a smart sensorwith RFID interface. Memory for shelf life data and history ispreferably separate from RFID memory. Interfacing is preferably via asensor bus to RFID chip. This enables interfacing to multiple vendorRFID implementations and multiple RF frequencies.

A “command-driven” architecture or a “memory map” may be used. Datasizes of different fields may be defined. A sample size may be 14 bits.Sampling may occur every 12 minutes or longer, and a lifetime may befive years or more. RFID readers may be provided with the software thatrecognizes RFID tags. A real time middleware or betweenware solution mayinterpret the data and may be able to print the data.

A table may be used wherein preferably less than 2 k bits of memory usesan advantageous communications protocol arrangement. Either of EPC/UHFClass1V2—256 bits of memory AND ISO HF I-Code may be used. Philips ISOU-Code HSL, ISO U-Code EPC 1.19, EPC Class 1 Gen2 or ISO I-Code chip maybe used. The Software may be implemented in chip and with RFID reader A32-bit memory block of which 8 bits represents a command and 24 bitsdata may be used. There may be no READ/WRITE command in chip, so thereader may write to the chip to tell it what it wants next. Memoryaddresses may be used over 8 k that the chip is not using, e.g., thenumber of addresses may be 128. The reader may, in this case, just readblocks of memory that are assigned address numbers to data in tag. Oftenan address will include only 8 bits. For either of these options, thememory layout for the design may be 32 bits on the tag or less. A QuickAlert area may be updated after each temperature sensing. It may includea command name in the case of the 8-bit command/24-bit data option. Datamay be input into chip at either assembly of the tag or at theperishable producer.

Exemplary data sizes are provided as follows:

Clock tick data=384 bits (16 bits; 24 table entries)

Delta (shelf life data)=384 bits (16 bits, 24 table entries)

Unique identifier=assumed most on wafer; serial number (64 bits); couldbe on wafer.

An EPC number (optional) for use by perishable producer for inheritanceor on standalone tags to identify perishable=96 bits

Device configuration data=about 128 bits

Histogram data=320 bits

Shelf life and custody logs=512 bytes

In operation, the smart labels 10 may be used to selectively andremotely locate a particular item or container and obtain data relatingto that item or container. FIG. 5 shows a collection of containers 34that may reside, for example, in a storage facility or warehouse. Inthis example, a user 30 having an RFID 32 reader can quickly and easilylocate a particular container. The user 30 enters into the reader 32 anRF identification command (e.g., a “where are you?” command), which isassociated with the RFID corresponding to the item that the user wouldlike to locate. Reader 32 transmits the identification command via an RFsignal toward the collection of containers 34. The RFID devices 18 insmart labels 10 receive the RFID signals including the identificationcommand. The specific RFID device corresponding to the identifier candetect the command and activate in response. The RFID devices notassociated with the particular identifier take no action. The sensor 10′that is coupled to the activated RFID device detects the command and/orthe activation of the RFID device and, in response, sends a command toindicator/switch 18. The command causes indicator/switch 18 to flashand/or illuminate and/or in the case of an audible indicator, togenerate an audible tone. The flashing display 18 and/or audible toneallow the user 30 to visually and/or audibly locate the desired item. Inone embodiment, the sensor 10′ will also communicate its freshness datain response to detecting the command. For example, the command may causethe sensor 10′ to activate in the following manner: i) flash in apredetermined manner (e.g., a location sequence) to allow a user tolocate the container/item; ii) pause for a predetermined period of time;and iii) flash in a manner that communicates freshness data and/or iteminformation. In an alternate embodiment, a user 30 may enter a separatecommand into the RFID reader 32 to cause the sensor 10′ to display itsfreshness information. Alternatively, when the smart label is enumeratedby the RFID signal, the sensor module may choose at random one of thevisual signaling schemes or may be instructed by the RF reader whichvisual signaling scheme to use. The smart label may then send sensordata to a conventional visual receiver or vision system in the visualcommunication scheme chosen. By using signaling schemes, the visionreader can handle partial or zero visual data. It should be understoodthat the particular examples discussed in this paragraph are in no waylimiting and any suitable command, command sequence and/or commandstructure can be used to trigger a particular sensor 10′ or itsassociated item and/or container, and to communicate data regarding theitem.

The visual/audible indicators of the foregoing embodiments may alsoenable visual and audio communications to replace or supplement RFcommunications by using signaling schemes to transmit data either to auser or to a special reader, such as one or more conventional visionsystems, photodetectors, pattern detectors, luminance detectors, orsound detectors. For example, a visual signal may comprise a flash of adot or a sequence of flashes of a suitable length of time sufficient fora vision system to read the data. This data can communicate descriptivefeatures of an item or condition, such as data the percentage ofremaining shelf life (100%, 85%, 50%), specific alert conditions(temperature has exceeded 8° C. for 20 sensing periods), and the like.

Visual data that a vision system receives may be converted and/orreformatted so that it is compatible with data received from theperishable indicator by an RFID reader. For example, the conversion mayallow the visual data to be incorporated into the supply chain and coldchain information systems used by RF readers. This visual data may benoted as visual data received, such as the ID of the visual receiver,location, time and other information tracked in RFID systems.

The visual/audible indicators of the foregoing embodiments furtherenable visual and audio communications to be initiated by an RF commandsent to the perishable indicator by an RF reader to either locate atagged item or to initiate a visual/audio communication link for thepurpose of transmitting data to and from the perishable indicator. Datatransmitted to the sensor can be shelf life data about an item to betagged, information about a shipment, a batch lot number, qualityinspection data or change of custody information. Data transmitted fromthe perishable indicator can be a temperature or shelf life log or othersensor data collected by the sensor such as humidity.

In one embodiment, a smart label 10 may be adapted to respond to andcommunicate with an RF reader that is shared at a checkpoint forinvoicing, billing or the like. The items-passing through the readermight be prompted by the reader to communicate their freshness data tothe reader. A textual, colored, or shaped indicia of shelf life, beingeither a symbol or index of such, could be added to line itemsregardless of Uccnet or EAn or ECP Global or other codes. In thismanner, by viewing a checkout or an inventory display screen, the readerdisplay, or a summary paper receipt, an ordinary employee or endcustomer could view the “freshness” or perishability of various items.Such an additional readout in the case of perishables permits anadditional benefit in the perception of merchandise quality. In oneembodiment, this read out may be used in lieu of a visual tag display toreduce the need for power to operate a tag display (or the cost perlabel or tag in having an operating individual item self-powered displayon each item), while still providing an RFID-cued indication offreshness. Alternatively, the smart labels passing through the readersmay be prompted to communicate their freshness data via their respectivedisplays.

FIGS. 6-8 illustrate further embodiments of the inventions, whichimplement an elongated or extended antenna interface. FIG. 6 shows asmart label 100 including an extended antenna interface 220, which isused to connect the sensor 110 to the RFID chip 180 and antenna 200. Thesmart label 100 includes a power supply or battery 120, a sensor module140, and an indicator/switch 160. The sensor module 140 is coupled toand receives electrical power from battery 120, which may comprise acoin cell, flexible battery or other relatively thin power supply. Thesensor module 140 may include sensor logic, such as a conventionalprocessor chip and/or circuitry, a memory module for storing data, suchas data related to a perishable item freshness data, or datarepresenting one or more predefined temperature-dependent shelf lifetrends, and a sensor component adapted to sense and/or detecttemperature and/or other item parameters. In alternate embodiments, thesensor module 140 may use external memory, such as the memory containedin an RFID device, to store item data and sensor measurements. Thesensor module 140 and RFID chip 180 may be substantially similar instructure and function to sensor module 14 and RFID chip 18,respectively.

The indicator/switch 160 may be communicatively coupled to the sensormodule 140 and may receive electrical power from battery 120. Theindicator/switch 160 may include a LED, OLED, LCD, light or othervisual, audio or otherwise humanly perceivable sensory indicator forproviding information regarding a monitored item and/or the “freshness”of the item that is being monitored. For example, the indicator/switch160 may comprise a multi-colored display (e.g., LED or LCD) adapted togenerate a different color based on a particular signal. In oneembodiment, the indicator/switch 160 may also include a conventionalelectrical or capacitive switch for selectively activating the displayand/or the sensor module 140, for example, by manually depressing theindicator/switch 160. The indicator/switch 160 may be substantiallysimilar in structure and function to indicator/switch 16 describedabove.

The smart label 100 includes an elongated or extended antenna interface220 for communicatively coupling the module 140 to RF transponder 180.The elongated or extended antenna interface 220 is preferably formedusing a thin, flexible substrate, which in one embodiment may comprisepolyester. In one embodiment, the entire smart label 100 is formed onthe flexible substrate. The extended antenna interface 220 can be aboutseveral inches to about 10 feet or more in length. Initial labels 100have been made with example lengths of 10 inches, 24 inches and 30inches. In one embodiment, the tag is covered front and back with labelstock comprising a flexible material, such as paper, tyvec, polyester orthe like. The back of the tag may also include an attachment material,such as double-stick tape, Velcro, adhesive or the like at one or bothends. The extended antenna interface 220 includes a pair of inductors222 that couple the interface to the antenna 200.

In one embodiment shown in FIG. 7, the sensor module 140 and antennainterface 220 are formed separately from the RF transponder 180 andantenna 200. In this embodiment, the sensor module 140 may beselectively and communicatively coupled to the RF transponder byattaching the antenna interface 220 to an RFID antenna 200. Thiscoupling is made using inductors 222. The inductors 222 allow the sensorcircuit to connect to the antenna we without detuning it and absorbingenergy. The inductors 222 present increasing resistance (impedance) tocurrent flow as the frequency increases (e.g., at low frequency theinductor is like a short circuit at high frequency it is like an opencircuit)—so at UHF the inductors act like an open circuit and isolatethe antenna 200/RFID chip 180 from the sensor module 140.

In another embodiment shown in FIG. 8, the smart label 100′ includes abattery 120 that is disposed in relative close proximity to the antenna200 and remote from the sensor module 140. In this embodiment, thesensor module 140 can be placed in a container while both the battery120 and antenna 200 reside outside of the container. This allows forextended battery life, for example, when a thermally cooled container isused. In another embodiment, the display/switch 160 can also be disposedin relative close proximity to the antenna 200 and remote from thesensor module 140.

In the embodiments shown in FIGS. 6-8, the extended interface 220 allowsthe sensor module 140/140′ to signal directly to the RFID chip 180 toupdate RF memory in the chip. The interface also allows the module 140to detect the incoming RF data so it knows when not to communicate withthe RFID chip 180. The inductors allow for signaling the RFID chipbecause the frequency required to do this at is only a few tens ofkilohertz and at this frequency the inductors look like short circuits.This allows the module to see the RFID chip through the inductors at lowfrequencies, while the UHF RF frequencies are blocked by the sameinductors. Detecting the incoming RF is also possible because the chipproduces a varying low frequency signal, which is resolvable at theantenna and again passes through the inductors. The inductors can beformed as a separate or integral component. For example, the inductorscan be designed as a coil etched/printed directly on the substrate or bebuilt as a micro strip inductor.

In operation, the sensor end of the smart label 100, 100′ is placed inthe container at the desired location. FIG. 9 shows a smart label 100being inserted into a container. Once inserted into a container theelongated antenna interface 220 may extend up the inside wall of thecontainer and over the top of the case so that the antenna 200 and RFIDchip 180 are located outside of the container. The thin, flexibleinterface 220, allows the lid to be placed on the container and seal thecontainer. The antenna end of the tag may be attached to the outsidewall of the container using the tape, adhesive or Velcro®.

The elongated smart label 100 is particularly useful in applicationswhere it is desirable for the sensor to be inside the package. Placingthe sensor module inside a package, such as a cold box, while allowingthe antenna to reside outside of the package provides variousadvantages. For example, and without limitation, the long tag allows foroptimal sensing and RF reception when used together with temperaturesensitive goods that are placed in a container lined with metal and/orcontaining ice or dry ice packs, which could reduce RFID readperformance. In one embodiment, the power supply or battery is placednear the antenna, remote from the sensor module. This allows the batteryto reside outside of a container, thereby eliminating risk that cold orfreezing temperatures cause battery voltage to drop. Additionally, along tag could be used to sense the temperature of cases located in themiddle of a pallet.

It should be understood that the inventions described herein areprovided by way of example only and that numerous changes, alterations,modifications, and substitutions may be made without departing from thespirit and scope of the inventions as delineated within the followingclaims.

What is claimed is:
 1. A condition monitoring system comprising aradio-frequency (“RF”) condition monitoring device comprising: an RFtransponder module comprising an RF transponder integrated circuit; atleast one monitoring module for monitoring one or more sensors, said atleast one monitoring module comprising an electronic device; a firstmemory and a second memory communicatively coupled to said RFtransponder module and said at least one monitoring module,respectively; a two-way communication interface between said firstmemory and said second memory; wherein one or more memory addresses insaid first memory are operative to store at least one of status andother data about a monitored item from said at least one monitoringmodule and to receive at least one of data, addresses, and commands sentby an RF reader to said RF transponder integrated circuit for the atleast one monitoring module; wherein said first memory is operative tostore data sent to or received from said second memory by way of saidtwo-way communication interface and said second memory is operative tostore data sent to or received from said first memory by way of saidtwo-way communication interface; wherein said first memory isoperatively responsive to route at least one of data and commands fromsaid RF reader to memory addresses in at least one of said first memoryand second memory by way of said two-way communication interface; acondition determining module for calculating a condition status of oneor more monitored items; and a condition control module comprising saidRF reader operative to communicate with said RF transponder module undersoftware control to control data sent to or received from memoryaddresses of said first memory or second memory of said RF conditionmonitoring device.
 2. The condition monitoring system according to claim1, wherein the item monitored is one of: a perishable, a device; or anitem having a measurable condition.
 3. The condition monitoring systemaccording to claim 1, wherein the item monitored is: an environment inwhich one of a perishable, a device; or an item resides, saidenvironment having at least one condition which can be measured.
 4. Thecondition monitoring system according to claim 1, wherein the conditionstatus comprises: at least one of a sensor value; an excursion of saidsensor value from a sensor of the one or more sensors or a timethreshold value; a life remaining of said item as expressed in time, alife remaining of said item in time at a specified sensing value, or alife remaining as expressed as a percentage of estimated life; a lifeused as expressed in time, a life used in time at a specified sensingvalue, or a life used as a percentage of estimated life; a number ofmeasured occurrences of a sensing in a specified elapsed time; a time orlife until a future event; or a visual or audio status of an item by auser or an audio-visual system.
 5. The condition monitoring systemaccording to claim 1, further comprises an audio-visual communicationinterface, under control of said electronic device, for supplementing orreplacing said two-way communication interface: said audio-visualcommunication interface using at least one audio or visual signalingscheme to transmit and/or receive data between said RF conditionmonitoring device and a user or audio-visual system, said audio-visualsystem comprising at least one of: a photodetector; a pattern detector;a luminance detector; a sound detector; or another vision or audiosystem.
 6. The condition monitoring system of claim 5, further comprisesan indicator communicatively coupled to said monitoring module, saidindicator comprising at least one of: an LED; an OLED; an LCD; aninfrared; a light; or a vision, an audio or otherwise humanlyperceivable sensor indicator for providing information regarding amonitored item, and further comprising; an electrical or capacitiveswitch for selectively activating the indicator and/or the monitoringmodule.
 7. The condition monitoring system of claim 6, wherein saidindicator further comprises: one or more signaling schemes, based upon:at least one of pulse length and pattern that generate: a time domainpulse sequence; Morse code; or a coding algorithm, to receive ortransmit data about a condition of an item.
 8. The condition monitoringsystem of claim 7, wherein said condition control module receives datafrom said audio-visual system, associates said data with sensor datacollected by said RF condition monitoring device; and stores said datain at least one of: said RF condition monitoring device, said conditioncontrol module; or a network or web database.
 9. The conditionmonitoring system according to claim 1, wherein said RF transponderintegrated circuit is operative to support at least one of: RFidentification (“RFID”), low frequency (“LF”), RFID high frequency(“HF”), RFID ultra high frequency (“UHF”), Bluetooth, Zigbee; and an RFair interface protocol.
 10. The condition monitoring system according toclaim 1, wherein said RF transponder integrated circuit is at least oneof: a passive, a battery assisted passive; or an active RF transponder.11. The condition monitoring system according to claim 1, wherein saidat least one monitoring module is operative to: receive a signaldirectly from said RF reader by way of the two-way communicationinterface; and to transmit monitored data directly to said RF reader.12. The condition monitoring system according to claim 1, wherein saidRF transponder integrated circuit comprises a one-wire or a two-wireserial interface.
 13. The condition monitoring system according to claim1, wherein said electronic device is a microprocessor.
 14. The conditionmonitoring system according to claim 1, wherein said electronic deviceof said at least one monitoring module is operative to initiate RFcommunication.
 15. The condition monitoring system according to claim 1,wherein said RF condition monitoring device comprises a single chip. 16.The condition monitoring system according to claim 1, wherein saidelectronic device of said at least one monitoring module comprises:software for at least one of controlling sensor setup and operations, anaudio and visual management, a power management, a data and memorymanagement; and a communication interface management.
 17. The conditionmonitoring system according to claim 16, wherein said data and memorymanagement software comprises: programming components for controllingone or more functions of the one or more sensors, including: a digitalcontrol function, a reading and writing control function; and an accesscontrol function, and is operative to transmit data to and receive datafrom said first memory by way of said two-way communication interface.18. The condition monitoring system according to claim 17, wherein thedigital control function, the reading and writing control function, andthe access control function are operative to: transmit data directly tosaid first memory or said second memory of the RF transponder and the atleast one monitoring module.
 19. The condition monitoring systemaccording to claim 17, wherein said data and memory management softwareis operative to: determine at least one of sensor status, said sensorstatus comprising: current sensor readings at a user determined sensinginterval, alerts that compare measured data with preset alerts rules;and a life used or left based on at least one of life predeterminedtrend tables and algorithms.
 20. The condition monitoring systemaccording to claim 1, further comprises: at least one second conditionmonitoring device; wherein said second condition monitoring device isoperative to: receive data about a condition of a monitored item fromthe RF condition monitoring device.
 21. The condition monitoring systemof claim 20, wherein the RF condition monitoring device and the at leastone second condition monitoring device are formed on a common substratein spaced-apart positions and are communicatively coupled, forcalculating a status of: one or more monitored items, storing the statusin the second memory; and storing the status in the first memory of theRF condition monitoring device and the at least one second conditionmonitoring device.
 22. A method of operating the condition monitoringsystem of claim 1, comprising: storing in said first memory commandsand/or data from said RF reader relating to: one or more monitoreditems; storing in said second memory data and/or commands from saidfirst memory relating to: said one or more monitored items; calculatinga status of said one or more monitored items in said second memory;storing in said second memory said calculated status of said one or moremonitored items; storing in said first memory the calculated status fromsaid second memory related to: said one or more monitored items; andtransmitting to said RF reader the calculated status.